Stamped ABS sensor bracket

ABSTRACT

A vehicle axle is provided that includes a spindle supporting a wheel hub having a toothed wheel. A tapered axle portion is adjacent to said spindle, and an ABS sensor bracket is secured to the tapered portion. The bracket has a body defining a hole receiving an ABS sensor adjacent the toothed wheel. The bracket includes a pedestal extending from the body and terminating in a base extending transversely from the pedestal. Reinforcing ribs may be used between the base and pedestal to strengthen the area. The base secured to the axle portion by a weld arranged in a notch in the base and another weld arranged at the rear of the base. The bracket is preferably secured to the axle by an automated process in which the axle is already precisely oriented for a procedure to the axle, such as the attachment of the brake spider.

BACKGROUND OF THE INVENTION

[0001] This invention relates to a vehicle axle incorporating anti-lockbraking, and more particularly, the invention relates to an anti-lockbraking system (ABS) sensor bracket used to support an ABS sensor on theaxle.

[0002] Commercial trailer axles incorporate ABS to better controlheavily loaded trailers during braking to prevent loss of control of thevehicle. The wheel hubs supported on the ends of the axle each have atoothed wheel that rotates with the hubs. An ABS sensor is supported onthe axle by a bracket proximate to the toothed wheel to detect therotation of the wheel hub. The sensor is connected to an ABS controllerthat monitors the rotation of the wheel hub during braking to detectlocking of the wheels. The controller commands the brakes to maximizethe braking force between the wheels and the roadway without locking upthe wheels.

[0003] The ABS sensor bracket is typically a solid piece of machinedmetal that is expensive to manufacture and secure to the axle. Thebracket has a pedestal with a bottom surface that is adjacent to an axleportion exterior. The bracket is secured to the axle by a weld bead oneither side of the pedestal. Since the bottom surface is flat, the weldbead must fill the gap between the bottom surface and the curved axleexterior to obtain a robust attachment of the bracket to the axle, whichis a difficult process to control. The bracket is secured to the axle ina separate operation in which the orientation of the axle is not closelycontrolled so that proper position of the bracket relative to the axleis not always achieved. Therefore, what is needed is a more costeffective ABS sensor bracket and method of attachment.

SUMMARY OF THE INVENTION AND ADVANTAGES

[0004] The present invention provides a vehicle axle including a spindlesupporting a wheel hub having a toothed wheel. A tapered axle portion isadjacent to said spindle, and an ABS sensor bracket is secured to thetapered portion. The bracket has a body defining a hole receiving an ABSsensor adjacent the toothed wheel. The bracket includes a pedestalextending from the body and terminating in a base extending transverselyfrom the pedestal. Reinforcing ribs may be used between the base andpedestal to strengthen the area. The base secured to the axle portion bya weld arranged in a notch in the base and another weld arranged at therear of the base. The bracket is preferably secured to the axle by anautomated process in which the axle is already precisely oriented for aprocedure to the axle, such as the attachment of the brake spider.

[0005] Accordingly, the above invention provides a more cost effectiveABS sensor bracket and method of attachment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Other advantages of the present invention can be understood byreference to the following detailed description when considered inconnection with the accompanying drawings wherein:

[0007]FIG. 1 is a perspective view of an axle with ABS using a prior artABS sensor bracket;

[0008]FIG. 2 is a side view of the prior art ABS sensor bracket;

[0009]FIG. 3 is a perspective exploded view of an ABS sensor beinginstalled into the prior art ABS bracket;

[0010]FIG. 4 is a side view of the present invention stamped ABS sensorbracket;

[0011]FIG. 5 is an end view of the bracket shown in FIG. 4;

[0012]FIG. 6 is a bottom view of the bracket shown in FIG. 4; and

[0013]FIG. 7 is a flow chart of a present invention method of attachingthe present invention ABS bracket to an axle.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0014] A prior art axle 10 is shown in FIGS. 1 and 2. The axle 10includes a spindle 12 that supports a hub 14 for rotation. The hub 14has a toothed wheel 16 secured thereto for rotation with the hub. Asolid metal ABS bracket 18 is secured to a tapered portion 20 adjacentto the spindle 12 by weld beads 22 on opposing sides of the bracket 18.The bracket 18 supports a sensor 24 proximate to the toothed wheel 16for sensing the rotation of the wheel hub 14. A cable 26 electricallyconnects the sensor 24 to an ABS controller. Referring to FIG. 2, thebracket 18 is located between a brake spider 28 and the spindle 12. Thespider 28 supports brake shoes 30 that are modulated by the controlleras necessary during braking to prevent the wheels from locking up. Asshown in FIG. 3, a pedestal 32 of the prior art bracket 18 is secured tothe axle 10 by weld beads 22 that must fill the gap formed between theflat bottom surface of the pedestal 32 and the axle portion 20. The bodyof the bracket 18 has a hole 34 that receives the sensor 24. A springclip 36 is arranged in the hole 34 between the body and the sensor 24 toretain the sensor in the bracket.

[0015] Referring to FIGS. 4-6, the present invention ABS sensor bracket37 is stamped metal. The bracket 37 may be manufactured using ansuitable forming process, such as progressive dies, to form the featuresof the bracket. The bracket 37 has a body with a portion 40 defining ahole 38 for receiving the sensor. The portion 40 includes a terminal end42 that is adjacent to the pedestal 46 and may be spaced there from toform a gap 44. The gap 44 is contiguous with the hole 38. The terminalend 42 may extend in the direction of the pedestal 46, as shown, or maydepend downward away from the hole 38.

[0016] A base extends transversely from the pedestal 46 and may includea notch 52 defining first 48 and second 50 toes. The toes 48 and 50 arepreferably greater than 90 degrees from the pedestal 46 and preferablyinclude reinforcing ribs 54 to ensure that the angle between thepedestal 46 and toes 48 and 50 are maintained. The base defines a planeP that is transverse to the axis A defined by the hole 38, whichaccommodates the slope of the tapered portion 20. A weld bead 53 isarranged in the notch 52 to secure the bracket 37 to the axle portion20. The notch 52 provides sufficient surface area to achieve a robustattachment and filling any gaps between the bracket 37 and the axleportion 20 is not of great concern. However, if additional support isdesired, a weld bead 57 may secure the rear surface 56 of one of thetoes to the portion 20.

[0017] During assembly 57 of the axle 10, which is schematicallydepicted in FIG. 7, the axle 10 is located in a desired orientation atan axle assembly station, as shown at block 60. Precise positioning ofthe axle is achieved to conduct an operation on the axle that requiresaccurate alignment relative to the axle, as shown at block 62. Forexample, assembly of the brake spider is done relative to the axle as issetting the camber of the spindle. With the axle in a precisely knownorientation, the stamped ABS sensor bracket 37 may be automaticallyplace on a desired location on the axle, as shown at block 64. A roboticarm may load the bracket 37 to the desired location, and the bracket maybe welded onto the axle, as shown at block 66.

[0018] The invention has been described in an illustrative manner, andit is to be understood that the terminology that has been used isintended to be in the nature of words of description rather than oflimitation. Obviously, many modifications and variations of the presentinvention are possible in light of the above teachings. It is,therefore, to be understood that within the scope of the appended claimsthe invention may be practiced otherwise than as specifically described.

What is claimed is:
 1. A vehicle axle comprising: spindle supporting awheel hub having a toothed wheel; an axle portion adjacent to saidspindle; an ABS sensor bracket having a body defining a hole receivingan ABS sensor adjacent to the toothed wheel, said bracket having apedestal extending from said body and terminating in a base extendingtransversely from said pedestal, said base secured to said axle portionby a weld.
 2. The axle according to claim 1, wherein said body includesa terminal end spaced from a portion of said pedestal forming a gap withsaid gap contiguous with said hole.
 3. The axle according to claim 1,wherein a reinforcing rib bridges said pedestal and said base.
 4. Theaxle according to claim 1, wherein said base includes a notch formingspaced apart toes.
 5. The axle according to claim 4, wherein said weldis disposed in said notch securing said toes to said axle portion. 6.The axle according to claim 5, wherein one of said toes includes a rearsurface opposite said notch with another weld securing said rear surfaceto said axle portion.
 7. An ABS sensor bracket comprising: a bodydefining a hole for receiving an ABS sensor; a pedestal extending fromsaid body with said body including a terminal end adjacent to a portionof said pedestal; and a base extending transversely from said pedestalfor securing to said axle portion by a weld.
 8. The bracket according toclaim 7, wherein a reinforcing rib bridges said pedestal and said base.9. The bracket according to claim 7, wherein said base includes a notchforming spaced apart toes.
 10. The bracket according to claim 7, whereinsaid terminal end is spaced from said portion of said pedestal forming agap with said gap contiguous with said hole.
 11. The bracket accordingto claim 7, wherein base extends from said pedestal at greater than a 90degree angle.
 12. The bracket according to claim 7, wherein said holedefining an axis with said base defining a plane at an angle relative tosaid axis.
 13. A method of attaching an ABS sensor bracket to an axlecomprising the steps of: a) locating an axle in a desired orientation atan assembly station; b) conducting an operation on the axle relative tothe desired orientation to obtain a desired predetermined alignmentbetween the axle and an axle component; c) stamping an ABS sensorbracket into a desired shape; d) placing the ABS sensor bracket on aportion of the axle at the assembly station; and e) welding the ABSsensor bracket onto the portion at the assembly station.
 14. The methodaccording to claim 13, wherein the component is a brake spider and theoperation is pressing and welding the spider to the axle.
 15. The methodaccording to claim 13, wherein the component is a spindle and theoperation is installing the spindle relative to an axle portion.
 16. Themethod according to claim 13, wherein the bracket includes a bodydefining a hole for receiving an ABS sensor, a pedestal extending fromthe body with the body including a terminal end adjacent to a portion ofthe pedestal, and a base extending transversely from the pedestal weldedto the axle portion.